Process for producing facsimiles



Oct. 8, 1940- c. GONGOLSKY PROCESS FOR PRODUCING FACSIIILBS Filed Jan.5, 1938 2 Sheets-Sheet 1 CHRlS Goneousxy INVENTOR ATTORNEYS Oct 8, c.GONGQLSKY 2,217,164

\ radcsss FOR Paonucfne mcsnuus Filed Jan. '5, 1938' 2 Sheets-Sheet 2CHRIS GON GOL$KY ATTORNEYS Patented Oct. 8, 1940,

UNITED STATES PATENT- OFFICE 2,217,164 PnocEss FOR PRODUCING FAcsimLEsChris Gongolsky, Brooklyn, N. Y. I Application January 5; 1938, SerialNo. 183,523

3 Claims.

This invention relates to improvements in processes for making molds andmore particularly to improvements in processes for making finelydetailed molds of ornamental bas-reliefs, such as so-called Wedgwoodware and the like.

It is a major object of the present invention to provide a process forproducing facsimile basreliefs which shall be economical and adapted tothe requirements of mass production and which shall also provide amethod for obtaining molds, faithful in detail, of relatively smallornamental objects.

It is another object of the present invention to provide a method ofobtaining positive and negative relief facsimiles of ornamentalstructures without materially altering the original structures, that isto say, it is an object of the invention and a feature of the process inaccordance therewith that an object such, for example, as

' a wedgwood plaque, vase or the like can be reproduced either as anegative or as a positive facsimile of the original withoutnecessitating any substantial alteration in the appearance or structureof the original object from which the facsimile is made.

It is another object of the present invention to provide a method forproducing metallic facsimiles of objets dart which are faithful indetail to the details of the original piece but which are economical asregards manufacture and especially are adapted to the requirements formass production.

It is a further object of the process according to the present inventionto provide means for the electrolytic production, in one piece, ofmetallic relief facsimiles whereby an irregular object, especially onehaving reliefs and under-cut figures on the surface thereof, can besubstantially reproduced without the necessity of separately molding aplurality of portions of the object and subsequently joining thesections of the mold together as is now the practice, or of molding theobject to produce a one-piece negative facsimile and then cutting themold or facsimile into sections to permit removal of the object aftermolding. It is also notable that in the process according to the presentinvention the aforesaid single piece metallic facsimile relief, positiveor negative, can be built up by processes including electro-depositionor spraying of hot metal upon the mold surface.

The invention will be fully and comprehensively understood from aconsideration of the following detailed description when read inconnection the rubber positive therefrom;

with the accompanying drawings which form part of the application. v

In the drawings- Fig. 1 is a side view of an object carrying basreliefsand under-cut figures on the surface thereof, being either the originalobject of which the facsimile is to be madev or the final positivefacsimile product;

Fig. 2 is a side view of the object illustrated in Fig. 1 showing, insection, a portion of the nega- 10 tive mold in place;

Fig. 3 shows the inflated rubber negative mol with supporting meansafter removal of the object being molded;

Fig. 4 shows the rubber negative mold of Fig. 3 with additionalsupporting means positioned circumjacent thereto;

Fig. 5 illustrates diagrammatically the preparation of a metallicpositive from the negative mold;

Fig. 6 illustrates substantially the same step in the process asillustrated in Fig. 5 except that a substantially flat instead of ahollow vase-like relief-carrying object is shown;

Fig. 7 illustrates a clay negative mold or facsimile with a rubberpositive facsimile positioned therein, parts being broken away forclearness;

Fig. 8 is a side view of a rubber positive facsimile after removal ofthe mold;

Fig. 9 is substantially a side view of the rubber facsimile shown inFig. 8 during the step of forming a metallic negative moldby sprayingsaid rubber positive facsimile with metal;

Fig. 10 shows substantially the same step as Fig. 9 except that theobject being treated is a 35 substantially flat relief surface insteadof a hollow vase-like object;

Fig. 11 is substantially a vertical sectional view of a metallicnegative facsimile after removal of Figs. l2, l3 and 14 are verticalsectional views 40 showing different methods of supporting rubberpositive facsimiles; and

Fig. 15 is substantially a diagrammatic elevational view showingelectrical circuit and apparatus used in electro-deposition of metalupon facsimiles in one step of the process according to the presentinvention.

' Regarded in certain of its broader aspects, the present inventioncomprises processes for preparing positive relief-carrying facsimiles bymeans including rubber molds whereby the object of which the facsimileis to be made is not substantially altered in any way during theprocess.

The process according tothe present invention 55 can comprise one of twomodifications, the first including the substantially direct preparationof a positive facsimile from the object to be copied and the othercomprising intermediate steps including the preparation of metallicnegative facsimiles.

In the following description, which is given purely by way ofillustration and in order to facilitate comprehension of the matter ofthe present invention, these processes will be discussed and describedin the order named; it being clearly understood that the specificembodiments of the present invention hereinafter referred to arenon-limitative.

According to the first of the hereinbefore mentioned processes, which'is best illustrated in Figs. 1 to 6 inclusive, it is desired to preparea metallic positive facsimile of an object, such as the vaselikestructure 20, having under-cut portions generally designated 2| andcarrying reliefs, one of which is indicated at 22, on the surfacethereof. In the first step of the process the object 20 is dipped in asolution or suspension of latex or similar material high in rubbercontent, sprayed or otherwise coated therewith whereby, referring nowto' Fig. 2, a film of plastic rubber-like material 25 is formed on theouter surface of the object of which it is desired to prepare afacsimile. It will, of course, be understood that, if desired, othercoating compositions instead of the aforementioned can be used, thedetermining factor in each instance being that the composition usedshould produce an extensible rubber-like coating substantially free fromair bubbles and the like. It will be noted that the plastic rubber-likefilm or coating substantially envelops the object and penetrates intoeven the smallest of the interstices of the reliefs carried on thesurface of the object especially when the fluid used is characterized byrelatively low viscosity and surface tension. It will be apparent, ofcourse, that the dipping or spraying can be continued until a film ofsubstantially any desired thickness and strength is formed upon thesurface of the object. The film or coating so prepared can then be driedor otherwise solidified and vulcanized, the latter being preferablyaccomplished by incorporating high speed low temperature vulcanizationaccelerators or analogous materials in the rubber mixture prior to thecoating operation, and thereafter peeled off or otherwise removed fromthe object.

It will be apparent that the solidified film forms a negative facsimileof the object 20, that is to say, the inner surface of the film willhave depressed and/or raised portions formed therein corresponding inlocation and magnitude to the raised or depressed configurations on thesurface of the object.

As hereinabove mentioned, after formation of the film on the surface ofthe object and solidification thereof, the film is removed in one pieceby stretching and/or peeling over and from the object being reproduced.The solidified negative facsimile so prepared, generally designated atreproduced, and also furnishing some, though small, support for thenegative during the next step in the process.

The outside parts of inflated negative 30 are then treated with asubstantially fluid but solidifiable material whereby a self-supportingcoating, generally designated at 35, is formed thereon, the negativebeing maintained inflated until the material is at least largelysolidified. It is preferred to form the coating of a material such aswax or similar easily fusible substance whereby the inflated negativefacsimile can be coated with molten material and .the material allowedto cool thereby hardening. The coating so formed, which is preferably atleast substantially adherent to the negative facsimile, serves toprotect and support same and to minimize distortion thereof duringsubsequent steps in the process.

The next step in the process involves the preparation of the finalpositive facsimile from the negative facsimile prepared as hereinbeforedescribed. Referring now to Fig. 5, after the supporting mediumsurrounding the negative facsimile has hardened sufficiently, asindicated by experience, the relationship between the block-like memberSI and the negative is severed and the interior of the negative moldsupported in the aforesaid manner is sprayed or otherwise coated withmetal. It will be noted that the object 40 so formed is substantially ametallic positive facsimile of the original object 20 and is providedwith raised and depressed localities corresponding to projections anddepressions on the original both in magnitude and location. Although itis preferred that the metallic positive facsimile be prepared byspraying the metal on the negative facsimile, it will be apparent ofcourse that other methods of coating can be employed. For instance, theinterior of the negative facsimile can be dusted with finely dividedgraphite or similar material and, using the conductive coating as acathode, metal can be electro-deposited therein. Or if otherwise deemedpreferable, metal can be directly molded in the negative facsimile, itbeing understood of course that a metal of relatively low fusing pointbe used, for instance so-called Wood's metal and the like. In thepreferred process however, a so-called atomic sprayer is employed whichusually comprises a stream of superheated metal fed into a current ofgas such as air under high pressure whereby molten metallic particlesare thrown against the surface. The metal so employed is usually heatedto a temperature substantially higher than the melting point of themetal in order that the particles will retain their fluidity andproperly coalesce upon striking a relatively cold surface, in thisinstance the negative facsimile. It will, of course, be apparent inspraying in this manner a mold or negative facsimile supported by amaterial characterized by a relatively low temperature of fusion, thatthe exterior of the mold, especially the readily fusible supportingmeans should be cooled, particularly if the metal being used has arelatively high melting point.

Substantially the same step, namely, prepara tion of the metallicpositive facsimile by coating the negative facsimile with metal, isdiagrammatically illustrated in Fig. 6, the difference being that inthis instance the object being reproduced isa relatively flat surfacehaving reliefs thereon.

Having thus described the first type of process according to the presentinvention, the second the outer parts thereof with supporting materialtype wherein metallic negative facsimiles are madewillnow be described.In this connection reference is made to Figs. '7 to inclusive,

' wherein certain features of the second type of.

process are best illustrated. a

In the process according to this embodiment of the present invention,theobject of which it is desired to prepare a facsimile reproduction, istreated in substantially the-same manner as hereinbefore describedwhereby a substantially elastic rubber-like negative film or facsimileis prepared, said negative facsimile being coated on as in accordancewith the hereinbefore described embodiment.

The supported negative facsimile is then filled with an easilydestructible medium adapted to fill and register the variousindentations and projections in the body of the negative. For example,experience indicates that a composition of this nature can be preparedfrom ingredients including glue and/or commercial gelatin which whenheated is substantially fiuid, or at least plastic, butwhen cooledexhibits gel-like characteristics. After the gel has set orsubstantially solidified within the negative facsimile mold, thesupporting material is removed from the outside parts -.of the mold andthe mold itself removed from the gel by peeling or stretching therefrom,care being exercised in this step of the process to prevent injury tothe facsimile details on the gel.

It will be apparent that the gel so prepared will be substantially apositive facsimile or reproduction of the original object from which therubber mold was prepared. The gel is then coated on the outside withclay or similar porous material,

for example plaster of Paris, whereby the details and surfacecharacteristics of the gel are reproduced in the coating material.Inthis manner a substantially porous, hard negative facsimile isprepared from the gel and after complete solidification and hardening ofthe negative, the gel is removed therefrom by any convenient physical orchemical means and the interior of the cleaned dried negative is coatedwith a rubber-like composition substantially as used in the preparationof the plastic negative mold described in connection with the firstembodiment of the present invention, whereby a substantially plasticpositive facsimile of the original object is produced. It will be notedthat the depressions and proturberances in the original object arefaithfully duplicated and reproduced in the rubber positive facsimile-both as regards magnitude and locality.

The positive facsimile positioned within the mold is illustrated in Fig.7 wherein the facsimile is designated by the numeral 50 and the mold bythe numeral 5|.

For purposes of illustration one method of preparing a positive rubberfacsimile has been hereinabove described but it will be apparent tothose skilled in the art that other processes of producing this resultcan,be employed without substan-' tial departure from the spirit orscope of the present invention. t

The rubber positive facsimile is removed from the plaster of Paris orclay mold preferably by peeling and stretching it from the walls of sameand after removal presents substantially the appearance illustrated inFig. 8. V

In the next step of the process the positive facsimile-is supported, forexample, by associating same with a block 60 having an opening thereincommunicating with a source of gas under pressure, generally designatedat 6|, in a manner I tallic positive facsimile therefrom.

substantially analogous to that described in connection with the firstembodiment of the inventio port can be employed, for example referringto Fig. 12, the positive facsimile can be filled with sand or the'likeor, referring to Fig. 13, the positive, 50, can be filled with separablecooperating blocks 63 forming a core generally designated at 64. Fig. 14shows the positive facsimile 60 supported within a vacuum chamber, itbeing noted that the chamber 65 connected with a vacuum line by the tube66 is at a substantially lower pressure than atmospheric and that theinterior parts of positive facsimile 50 are open to the atmospherewhereby the facsimile is supported substantially as shown.

The next step in the process comprises treating the supported positivefacsimile with an easily fusible metal whereby a self-supporting coatingof metal is formed on the surface of the facsimile thereby producing ametallic negative facsimile. This step in the process is illustrated inFigs. 9

a vase-like object and the latter in connection with a flat plaque-likeobject 10, whereon is shown a coating of metal II. It is preferred thatthe metal be deposited upon the positive facsimile by spraying although,of course, other methods of deposition can be employed if deemeddesirable.

When the outer surface of the positive facsimile has been substantiallycoated with metal Ifdesired, however, other means of supand 10, theformer showing it in connection with and the metal fully solidified toprovide a selfsupporting negative facsimile therearound, the positivefacsimile is withdrawn from the interior of the negative facsimile bypeeling or stretching the former, the latter, generally designated atI0, after removal of the positive facsimile Presenting substantially theappearance shown in Fig. 11.

It will be apparent that in following the hereinabove described steps inthe process according to this embodiment of the present invention, ametallic negative facsimile 10 of the original object has been prepared,the interior of which is 7 characterized by depressions andprotuberances corresponding both in magnitude and locality toprotuberances and, depressions in the original object of which thepositive facsimile is being prepared.

It is preferred in preparing the metallic negative facsimile ashereinbefore described that the characterized by substantially lowmelting point,

- 22.9% tin, and the balance lead.

Having prepared an easily fusible negative facsimile as hereinbeforedescribed, the next step in the process comprises the preparation of ame- In this connection reference is made to Fig. 15 wherein a system forelectro-depositlon is diagrammatically illustrated.

Referring now to Fig. 15, a pair of substantially readily fusiblemetallic negative facsimiles 80 and BI are shown positioned upon anelectrically con- 50 metal used in the fabrication of the facsimile be Iductive plate 82 associated with one pole of a generator 83, the otherpole of said generator being electrically connected to a pair of anodes84 and 85. It will be noted that, with connections established asaforesaid, the negative facsimiles 88 and 8| serve as cathodes and themembers 84 and 85 as anodes when an electrolyte at least partially fillsthe interiors of said negative facsimiles. A tank 81 associated with thesupply line 88 is provided to feed the lines 89 and 9ll,'connected tothe caps 9| and 92 covering and sealing the negative facsimiles 88 and8| substantially as shown, it being understood of course that although agravity feed system is 11-. lustrated, other means can beemployed ifdesired to insure flow of electrolyte into the negatives. Similarly,outlet lines 93 and 94 carry spent liquor to the line 95 from whence itpassesto a storage tank 96 and thence by means of a It will be apparent,of course, that although only two negative facsimiles are shown in theillustration a greater or lesser number can be used if desired by properextension of the plate 82, the lines 88 and 95 and cooperating lines. Inuse a fluid electrolyte is placed in the tank 81 whereby, throughgravity, it flows through the lines 89 and 90, circulates within theinteriors of the negative facsimiles and 8|, passes out through thelines 93 and 94 to the line 95, thence to the storage tank 96 fromwhich, by means of the pump 91, it is returned to the tank 81. It willbe understood, of course, that air or other gases, trapped within thefacsimiles 88 and 8| above the open end-of the lines 93 and 94, will beat least mostly removed prior to sealing the covers 9| and 92 upon saidfacsimiles.

Positive facsimiles are prepared from the substantially easily fusiblenegative facsimiles, prepared as aforesaid, by electro-depositing metalupon the interior parts of the negative facsimiles, utilizing, insubstance, the apparatus illustrated diagrammatically in Fig. 15. Itwill, of course, be understood that the weight or thickness of thepositive facsimile so prepared can be varied by altering and controllingthe current flowing through the electrolyte, as well as the time inwhich the current is passed. It is also to be understood that the anodes84 and 85 can be varied in composition to accord with the composition ofthe electrolyte and the metal in which it is desired to deposit. Forexample, if it is desired to deposit gold, gold anodes are used and anelectrolyte of potassium auri-cyanide is used, or if preferred a bath ofaurictri-chloride is used. Similarly, if it is desired to produce afacsimile in nickel, nickel anodes are employed and a bath of nickelsulphate or similar material commonly known and used inelectro-deposition. Other electrolytes and anodes can be used in asimilar manner. Experience indicates that suflicient agitation ofelectrolyte occurs by disposing the outlet parts of the lines 89 and 98and the inlet parts of lines 93 and 94 substantially as shown.

It will be apparent that after electro-deposition of metal within theinterior of the metallic negative facsimile, the product will be asubstantially composite structure comprising a relatively easily fusibleshell with a metallic positive facsimile positioned therein. Thepositive facsimile having been prepared of relatively infusible metalsuch as, for-example, copper, nickel, gold, platinum or the like, it isremoved from association with the relatively fusible negative facsimileby melting the latter. The product so obtained is characterized inpossessing indentations, depressions, protuberances and projectionssimilar to and corresponding in magnitude and locality to analogouscontour characteristics of the object before described areespeciallywell adapted to the needs of mass production, for example, inthe first described embodiment of the present invention it will be notedthat the rubber negative facsimile 30 can be used many times withoutreplacement by returning the facsimile after use in the step illustratedin Figs. 5 and 6 to the step illustrated in Fig. 3 and repeating thesubsequent operations. Thus it will be seen that in the first describedembodiment of the invention the preparation of the negative facsimile isthe" only step in the process not cyclical.

Similarly, in the second described embodiment of the invention it willbe noted that the rubberlike positive facsimile, after use in the stepillustrated in Figs. 9 and 10, can be used again merely by removing thefacsimile from the interior of the substantially fusible metallicnegative facsimile, supporting it and again spraying it with metal. Itwill, of course, be obvious that the fusible metal used in thepreparation of the negative facsimile in the step illustrated in Figs. 9and 10, can be recovered after removal from the electro-positivefacsimile, to be subsequently re-used.

It will also be obviousto those skilled in the art that the weightand/or thickness of the metallic positive facsimiles produced accordingto 3 the hereinabove described processes can be varied according to theuser's requirements, these characteristics being merely dependent uponthe amount of'metal deposited, whether by' spraying, electro-depositionor other means, upon the negative facsimiles.

As hereinbefore mentioned, either or both of the processes hereinabovedescribed can be utilized for the reproduction of relief-carryingobjects whether the reliefs be 'stiacciato as in coins, bassoormezzo-rilievo, wherein the figures are in relatively low relief, that isto say the cutout figures are exposed to 'an extent substantially notmore than half their circumference, as well as in relatively high reliefor alto-rilievo, wherein the figures are exposed to an extentsubstantially greater than half their circumference. It is inapplications of the last mentioned type that the presentinvention is ofespecial value inasmuch as it provides means, it is thought, for thefirst time, or preparing facsimiles of this type of relief.

It is to be understood that this improvement is capable of extendedapplication and is not confined to the exact showing of the drawings norto the precise construction described and, therefore, such changes andmodifications may be made therein as do not affect the spirit of theinvention nor exceed the scope thereof as expressed in the appendedclaims.

What is claimed is:

1. Process for preparing one piece positive facsimiles of undercutobjects having relief figures on at least one face thereof, comprisingforming a substantially elastic one piece negative facsimile directly onsaid-object, extending parts of said one piece negative facsimilewhereby saidobject can be removed therefrom without substantiallyaltering the. relationship of parts and figures on said object,supporting said negative facsimile whereby the figures and parts thereonare disposed in relationship relative to each other substantiallycorresponding to the relationship between similar parts on the object,preparing a substantially elastic one piece positive facsimile from saidnegative facsimile, supporting said positive facsimile whereby cutawayparts and relief figures thereon are disposed in a relationshipcorresponding to that of equivalent parts on the object, coating saidelastic positive facsimile with a relatively easily fusible metalwhereby a metallic negative facsimile is produced, stretching parts ofsaid one piece positive facsimile whereby said metallic negativefacsimile can be dissociated therefrom, removing said negativefacsimile, electro-depositing relatively difiicultly fusible metal uponportions of the surface of said metallic negative facsimile, and fusingsaid negative facsimile whereby said relatively difiicultly fusiblepositive facsimile can be separated therefrom.

2. Process for preparing one piece positive facsimiles of undercutobjects having relief figures on at least one face thereof, comprisingforming a substantially elastic one piece negative facsimile directly onsaid object by coating same with a solidifiable rubber-containingmixture, at least largely solidifying said coating, extending parts ofsaid one piece negative facsimile whereby said object can be removedtherefrom Without substantially altering the relationship of parts andfigures on said object, supporting said negative facsimile whereby thefigures and parts thereon are disposed in relationship relative to eachother substantially corresponding to the relationship between similarparts on the object, covering the useful faces of said negativefacsimile with a solidifiable material, solidifying said material,removing said negative facsimile therefrom whereby a positive facsimileformed of said material is obtained, supporting said positive facsimilewhereby figures and cutaway parts thereon are disposed in substantiallythe relationship of corresponding parts on the object, coating saidpositive facsimile with a hardenable composition, hardening saidcoating, removing said positive facsimile from relationship with thematerial coating same without severing said coat- 7 ing, coveringportions of said hardened coating with solidifiable plastic material,solidifying said material, removing said coating from said solidifiedplastic material, spray-coating said solidified plastic mass withrelatively fusible metal whereby a metallic negative facsimile isobtained, stretching parts of said one piece positive facsimile wherebysaid metallic negative facsimile can be dissociated therefrom, removingsaid negative facsimile, electro-depositing relatively difficultlyfusible metal upon portions of the surface of said metallic negativefacsimile, and fusing said negative facsimile whereby said relativelydiflicultly fusible positive facsimile can be separated therefrom.

3. Process for preparing one piece positive facsimiles of undercutobjects having relief figures on at least one face thereof, comprisingforming a substantially elastic one piece negative facsimile directly onsaid object, extending parts of said one piece negative facsimilewhereby said object can be removed therefrom without substantiallyaltering the relationship of parts and figures of said object,supporting said negative facsimile whereby the figures and parts thereonare disposed in relationship relative to each other substantiallycorresponding to the relationship between similar parts on the object,preparing a substantially elastic one piece positive facsimile from saidnegative facsimile, supporting said positive facsimile whereby cutawayparts and relief figures thereon are disposed in a relationshipcorresponding to that of equivalent parts on the object, coating saidelastic positive facsimile with a relatively easily fusible alloy ofbismuth, lead, and minor proportions of other metals whereby a metallicnegative facsimile is produced, stretching parts of said one piecepositive facsimile whereby said metallic negative facsimile can bedissociated therefrom, removing said negative facsimile,electro-depositing relatively difficultly fusible metal upon portions ofthe said metallic negative facsimile, and fusing said negative facsimilewhereby said relatively diflicultly fusible positive facsimile can beseparated therefrom.

CHRIS GONGOLSKY.

